Check that the ratchet actually works and the pedal is pulling the cable from the very first milimeters of pedal movement.

You can get bigger size wheels for the ratchet to give more travel. They are colour coded.

You must use the correct hole for the cable depending on if oyu have the short or long arm fitted. AFAIK, only mk3s used a short one. The short one will gove more travel though.

If you have a AP-clutch or other heavy duty organic, then at least AP advises to fit the later escort pedal completely to avoid these problems.